Helmet Protection System

Abstract

According to some embodiments of the invention, a system for protecting a device formed from polystyrene is provided. The system includes a body formed from polystyrene. The system also includes a protective layer formed from thermoplastic elastomer. The protective layer is coupled to the body during a molding process used to form the body.

1 . (canceled)  
   
   
       2 . (canceled)  
   
   
       3 . (canceled)  
   
   
       4 . (canceled)  
   
   
       5 . (canceled)  
   
   
       6 . (canceled)  
   
   
       7 . (canceled)  
   
   
       8 . (canceled)  
   
   
       9 . (canceled)  
   
   
       10 . (canceled)  
   
   
       11 . A method for providing a protective layer, comprising: 
 providing a clam shell mold defining a chamber;    positioning a protective layer of thermoplastic elastomer in the chamber;    after positioning the protective layer, providing expanded polystyrene in the chamber; and    heating the expanded polystyrene in the chamber.    
   
   
       12 . The method of  claim 11 , wherein the chamber comprises a shape of a helmet.  
   
   
       13 . The method of  claim 11 , wherein heating the expanded polystyrene comprises exposing the expanded polystyrene to steam.  
   
   
       14 . The method of  claim 11 , wherein providing expanded polystyrene comprises providing expanded polystyrene so that the protective layer is disposed on an outer surface of the expanded polystyrene after the method is complete.  
   
   
       15 . The method of  claim 11 , wherein the chamber comprises a shape of a helmet having an outer surface, an inner surface, and a rim portion disposed between the outer surface and the inner surface, and positioning the protective layer comprises positioning the protective layer at a portion of the chamber that has a shape of the rim portion.  
   
   
       16 . The method of  claim 11 , wherein the protective layer is a first protective layer, and further comprising positioning a second protective layer of plastic shell in the chamber before providing the expanded polystyrene.  
   
   
       17 . The method of  claim 11 , wherein the clam shell mold comprises a first side and a second side, positioning a protective layer comprises positioning the first protective layer in the first side, and positioning a second protective layer comprises positioning the second protective layer of plastic shell in the second side of the clam shell mold.